91 X by black91EB

[black91EB]

Your ex looks pretty muddy but did I notice a sagging drivers door? maybe it was not closed all of the way or something. Mine is sagging and needs new pins is why I'm asking [/

It needs some new pins, bushings and is missing 2 of the 4 bolts on the hinges. Also, if you look at the pics on the first page, you can see that the rear door is messed up, and has been poorly repaired. I need to fix it, but have been very short on time, due to school. I will be sure to post pics when I do get around to fixing it, so that others have an idea.

 

[black91EB]

so, not much lately, did do some wheeling the other night, but didnt get a chance to take pics.

The chrome unity light on my door pillar bit the dust, it wouldn't rotate anymore due to a broken shaft. I installed a new (to me) black one, which looks alot better, in a much better mount. The mount I was using was a modified crown vic mount, and it would not hold the light securely once I modified it for the different angle of an explorer pillar. The new mount is fabricated from 3/8" black iron pipe and welded to the pillar. I also finally got around to notching the door, so it will shut properly now.
Should have pictures up in the next few days.

 

[black91EB]

well, sorry to all about the lack of pictures, something about a broken camera.

The explorer became an exploder the other night. I was on the way home and blew the passenger side head gasket. This resulted in massive amounts of white smoke as coolant entered the cylinders. I am now in the process of putting the engine out of a 96 sport in it now, since it runs really well, has good compression, and about half the miles. I momentarily considered replacing the gasket, but I figured since my engine had around 215K on it, it was probably worthwhile to put something a little fresher in its place.

List of issues that will be rectified by this engine swap:

Steady coolant loss (I think the head gasket has had a small coolant leak for a while)
Serious lack of power and gas milage
The infamous 4.0L lifter rattle
Persistant engine oil leaks
Leaky Power Steering pump (I know, it's a Ford, but some leak worse than others)
Slightly slipping clutch
Noisy throwout bearing

While I have it apart I will probably do an add a leaf and maybe some 2wd f150 spacers just to make it have a little less sag and a little more clearance. Will probly do a disk brake conversion too.

Anyway, the intake and other assorted engine management parts from the donor truck will be in the for sale thread if anyone needs such for a 96 OHV engine.

PS, this is post 222 for me, kinda funny.

 

[black91EB]

well, my ex is now engineless. Have 2 engines on stands side by side so I can swap over the intake and oil pan and such. Found something else interesting while I was pulling the engine, I found that the passenger side engine mount bolt was snapped off. That would explain the excessive shifter movement under load... Once I get a memory card adapter I will upload some pics. Only have cell pics now due to the fact that my camera met an early demise.

 

[black91EB]

This has been one of the most frustrating engine swaps in history. Not only did I run into the above mentioned issues, but in addition:

Stripped 2 of 3 thermostat housing bolt holes (helicoil to the rescue!)

Broke off the bolts in not 1, not 2, but 3 driver's side exhaust manifolds, after using PB Blaster and heat. This is easier than it sounds. A trip to U-Pull-It later, back in business. Coverted to studs with the handy "Help!" kit from autozone, so hopefully wont have this issue again.

Bolt holes for 1st gen engine mount plates on the '96 engine were rusty and full of dirt to the point I couldnt even start a bolt. Trip to the store to get a tap, back to work.

Changing out the passenger side engine mount proved to be a major PITA. You really have to wonder WTF the ford engineer was thinking when they designed how that thing goes on.

List of tools broken thus far:
Craftsman 15mm 3/8" drive 6 point, x2
Craftsman 10mm 1/4" drive
Craftsman 6" locking 1/4" drive extension
no-name 3" 1/4 drive extension
Craftsman pro series 1/4" drive ratchet
Craftsman standard 1/4" drive ratchet, x2
Craftsman flex head 3/8" drive ratchet
Craftsman 3/8" drive universal
Napa 3/8" drive universal
Stanley 1/2" drive universal
Stanley groove joint pliers
Craftsman hose clamp tool
Craftsman 1/2" to 3/8" adapter, x2

(They know me almost by name at the local Sears, lol)

Pictures are coming, eventually. Have been taking them as I go along.

 

[MrQ]

Uhoh. I have broken a couple of tools on my truck, but nothing like that.

 

[black91EB]

yeah, and all that on one project. The first time I worked on this truck I broke a 1/2" universal and 3 15mm sockets. Guess my truck hates craftsman.

 

[black91EB]

Well, got it all put back together. Runs beautifully, more power than its had since I have owned it, and the new clutch doesnt hurt. (Just have to take it a little easy till I get that broken in properly) Anyway, sorry for the delay on some pics, but I have dial up internet at home so it takes forever to get pictures uploaded. I should be able to by the end of the week though


Made it through the rest of the project without breaking anything else too!

 

[MrQ]

You really need to move this to the elite registry.

 

[black91EB]

You really need to move this to the elite registry.

Yeah, will most likely contact the moderator about that.

Drove it alot more today, even hit some trails. The old engine must have been really tired because this one pulls so much better. It has a whole lot more power, in addition to being much more responsive.

I will say I had a few worried moments when I started it up last night, first off, it had what sounded alot like a rod knock for about the first 3-4 minutes, but that went away and has not returned. Then, once the catalytic converter got hot, all the coolant that had found its way in there from the blown head on the old engine started to smoke, which really did not make me feel good. But, like the knock, it went away and hasn't returned.

 

[black91EB]

That better MrQ?

 

[black91EB]

well, just when all was going well, I smelled fuel this morning and popped the hood, to discover I have a leaking fuel injector o-ring. So, off comes the upper intake and fuel rail, again, so I can change it out.

 

[MrQ]

That better MrQ?

Much better!

 

[black91EB]

Well, I figured it was time, and your prompting just sped things up a bit.


Well, I broke something else. This is a ford factory part, found used in a JY for 5 bucks. Though I will say it has served me admirably the past year and a half it has been on the truck.

 

[MrQ]

Nice shatter. I bet that wasn't the Warns. :

 

[black91EB]

no, not warn. The annoying part was having to carry the floor jack almost 200 yards to jack it up in 6" deep mud, since the factory jack just did its best impression of a spike. Swapped it out and drove on out. (2wd just wasn't cutting it, even in low range)

 

[black91EB]

Engine swap pictures, finally, what few there are.

Engine out of '96 sport:

Engines on stands in front of my truck

Valley of old engine. If you look carefully you can see the brown spots where the coolant had mixed with the oil.

Oil out of old engine. Not a good thing.

This is the stud conversion I was talking about. Much much nicer than the stupid bolts I broke 5 of.

 

[MrQ]

What was the matter with the sport? Transmission?

 

[black91EB]

Yeah, and it had some rust, and was lightly wrecked on the rear. Thought about fixing it untill I realized how hard it was to find a '96 4x4 4R55E. I will most likely do something with the sport. V8 5spd SAS sounds about right...

 

[MrQ]

Could have dropped in a manual... M5OD was used till right before 2000 I believe.